EMBROIDERY · IN HOUSE

Embroidery that makes a blank read as a brand.

Logos, 3D puff, appliqué, patches and woven labels, stitched in house in Tirupur. Digitising of embroidery files is handled within the group, so artwork does not leave our control.

Embroidery is the only decoration built from thread rather than ink. A digitised file tells the machine where every stitch goes, and the needle builds the design directly into the fabric. Nothing is printed, nothing is coated and nothing can crack or peel.

That is why it is the default for anything that has to look considered rather than printed. A small embroidered chest mark on a heavyweight hoodie or a clean polo does more for perceived value than a much larger print, because the texture and the slight relief read as investment.

We run embroidery in house alongside DTG, DTF and sublimation, and digitising happens within the group rather than being sent out. Digitising is where an embroidered logo is won or lost, so keeping it inside lets us tune density and underlay for your actual fabric.

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// At a glance

Where it runsIn house, Tirupur
DigitisingWithin the group
TypesFlat · 3D puff · Appliqué · Patches
FabricsKnits and wovens, with backing
DurabilityHighest, thread not ink
MOQ / colourFrom 50 pc
// What we stitch

Five kinds of embroidery work

Flat embroidery

Standard stitched logos and lettering, laid flush to the fabric. Satin stitch for clean edges on lettering and outlines, fill stitch for larger solid areas. The workhorse for chest marks, sleeve hits and back yoke branding.

3D puff

Foam is laid under the stitching and trimmed away after, leaving a raised, sculpted edge. It reads bold and premium on heavy fleece and on caps. It needs simple shapes and generous stroke weights, because foam cannot hold fine detail.

Appliqué

A shaped piece of fabric is laid down and stitched around its edge, so a large block of colour is covered in cloth rather than thread. Lighter, faster and softer than filling the same area with stitches, and it brings a contrast fabric into the design.

Patches

Embroidered and woven patches produced separately, then attached to the garment. Useful when a design is too dense to stitch directly, or when the same badge crosses several garment types in your range.

Woven labels

Neck labels, hem tabs, side-seam flags and care labels woven to your artwork. Often the branding element a customer notices first when they try the garment on.

Combined builds

Appliqué with a satin stitch border, or puff lettering over a flat fill. Most premium pieces use two techniques together.

Stitching line at the Zorixo Garments factory in Tirupur

Stitch count and placement basics

Two things decide an embroidered design: how many stitches it takes, and where it sits.

Stitch count is driven by the area you fill and how densely you fill it, not by how many thread colours you use. A solid filled shape carries far more stitches than an outlined version of the same mark. If a design comes back expensive, the fix is to open it up, switch a fill to an outline, or move a large block to appliqué, rather than to cut the palette.

Placement has to respect the garment, not just the layout. Left chest, centre chest, sleeve, back yoke, nape, hem tab and cap front are the standard positions, and each is hooped differently. Anything crossing a seam, pocket, zip or rib is harder to hoop flat and can pucker, so we either move it or engineer the placement into the cutting stage before assembly.

  • Small lettering needs a minimum height to stay legible, because a satin stitch has a physical minimum width. Very small text usually turns into a printed element or a woven label instead.
  • Fine detail simplifies. A logo with hairline rules and tight counters will be redrawn for thread, and we show you the result before bulk.
  • Heavy fleece and French terry need topping so the stitches sit above the pile instead of sinking into it.
  • Stretch and performance fabric needs careful stabilising, or the panel puckers around the design once it relaxes.
How we inspect decoration →
// Durability, artwork & cost

What to expect, and what to send

Durability

The longest lasting decoration available alongside sublimation, and for a different reason. There is no ink to fade, no film to crack and no adhesive to fail. A properly backed embroidered logo outlasts the garment it sits on, through hot washing and tumble drying that would destroy a surface print. The one weakness is mechanical: long satin stitches can snag, so we keep stroke lengths sensible and back the design tight against the cloth.

Fabrics it suits

Almost everything, with the right backing. Woven fabrics and stable knits like pique are easiest. Jersey, terry and fleece all embroider well with an appropriate stabiliser, and heavy pile takes a topping so detail is not swallowed.

The cases needing care are high-stretch performance panels, very lightweight fabric a dense design would overwhelm, and anything with a coating a needle would perforate. We flag these at sampling rather than at bulk.

Artwork requirements

Send vector artwork where possible, text converted to outlines, at the intended finished size. A high resolution raster file also works. Tell us the position and approximate finished width, and name your thread shades or let us match to a thread shade card.

Digitising is a redraw, not a file conversion. Your artwork is rebuilt as stitch paths, with underlay, density, pull compensation and stitch direction chosen for your fabric. That happens inside the group, and we send a stitched sample on the real fabric before bulk.

Minimums and how cost behaves

From 50 pieces per style per colour, with sizes splitting freely inside a colourway. Embroidery is efficient at low quantity, because the only one-off work is digitising, paid once per design no matter how many reorders follow.

After that, per-piece cost tracks stitch count and machine time almost linearly. A dense filled back piece costs many times a small outlined chest mark. Extra thread colours add change time but little else, and each extra placement adds its own hooping. Quantity brings modest efficiency rather than the steep curve of screen printing.

Decoration is quoted inside your unit cost once the artwork, the placements and the quantity are fixed. Nothing on this page is a price.

// Questions

Embroidery: common questions

Digitising is a one-off preparation step per design, handled within the group rather than sent to a third party. It is paid once and reused across every reorder and every garment carrying the same mark at the same size.

Legibility runs out before the machine does. A satin stitch has a minimum practical width, so below a certain letter height the strokes merge and the counters close up. We will tell you when your text is under that threshold and suggest a woven label instead.

Size and fill density, through stitch count. Thread colours add machine change time but not much cost. To bring an expensive design down, reduce the filled area, switch a solid block to an outline, or move it to appliqué.

Yes, using a topping that holds the stitches above the pile plus backing underneath for stability. Heavy fleece is also one of the best surfaces for 3D puff.

Yes, and it is a common premium build: embroidered left chest, printed back graphic, woven label at the hem. Each placement adds a handling step, so it moves the unit cost and the lead time.

From 50 pieces per style per colour, sizes split freely. Sample lead time runs 10 to 22 days and bulk 25 to 55 days depending on the product and decoration load. See how low MOQ production works.

Send the logo. We will stitch it on your fabric first.

Digitising, a sample on the real cloth, then bulk. From 50 pieces per colour.

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